Battery pack safety monitor

ABSTRACT

A battery pack monitor includes a portable housing, a controller within the housing, and a memory communicatively connected to the controller. The battery pack monitor further includes a power source positioned within the housing and operatively connected to the controller. The battery pack monitor includes a battery pack connector comprising a wired battery interface electrically connectable between the controller and a battery pack management system of a high voltage battery pack. The controller includes executable instructions which, when executed, cause the controller to receive, via the wired battery interface, status information from the high voltage battery pack, store the status information in the memory, and based on the status information, generate one or more battery status alerts. In examples, the battery pack monitor includes a wireless interface for communication with a remote system for logging status information, and may have a diagnostics connector to allow connection of additional diagnostic equipment.

BACKGROUND

High voltage (HV) battery packs are manufactured at scale for use in battery-electric vehicles. Such battery packs typically include a large number of lithium ion (Li-ion) battery cells which are assembled and electrically connected in series to achieve high voltage levels. Each high-voltage battery pack will typically include a plurality of high voltage connectors useable to charge the battery cells, as well as a battery management system that may include a low voltage input/output and a wired (connectorized) communication interface.

When installed for use within a battery electric vehicle, the state of the HV battery pack is typically monitored, for example by monitoring the state of charge (SOC) and state of health (SOH) parameters that are generated and able to be communicated from the battery management system (BMS) of the battery pack to other vehicle subsystems. Furthermore, when installed in a stationary application (e.g., at an electric power bank), permanent facility-wide circuitry may be electrically connected to each battery pack for monitoring purposes. However, while an HV battery pack is in storage, in transit, or during manufacturing the battery pack may experience safety concerns, such as thermal runaway (a chain reaction within a battery cell occurring when a temperature reaches a point at which a chemical reaction occurs within the cell). Furthermore, SOC/SOH parameters may be difficult to readily access, either remotely or locally, when such battery packs are in storage or transit. Typically, monitoring of HV battery pack parameters involves use of cumbersome, large-scale monitoring equipment. The size, cost, and complexity of such systems make widespread use undesirable.

SUMMARY

In general, a battery pack monitor is provided, for example which may be electrically connected to a high voltage battery pack to receive state information from a battery management system of such a battery pack. The battery pack monitor receives battery state information from the battery management system. The battery state information can include SOC/SOH parameters, as well as alert information generated by the battery management system associated with detected events indicative of a safety concern. The battery pack monitor can log that data and/or display alerts and/or status information about the high voltage battery pack. The alerts may indicate existence of a safety concern, such as a thermal runaway event, which may require intervention by facility personnel. In some instances, the battery pack monitor may also communicate with a remote system, such as a cloud server, to communicate the battery state information; the remote system may receive such information associated with a plurality of battery packs and may analyze that data for purposes of warranty tracking, component quality assurance, performance trends, and the like.

In one particular example aspect, a battery pack monitor includes a portable housing, a controller within the housing, and a memory communicatively connected to the controller. The battery pack monitor further includes a power source positioned within the housing and operatively connected to the controller. The battery pack monitor includes a battery pack connector comprising a wired battery interface electrically connectable between the controller and a battery pack management system of a high voltage battery pack. The controller includes executable instructions which, when executed, cause the controller to receive, via the wired battery interface, state information from the high voltage battery pack, store the state information in the memory, and, based on the state information, generate one or more battery alerts.

In a second example aspect, a battery pack monitoring system includes a battery pack dongle configurable for wired connection to a battery management system interface of a high-voltage battery pack. The battery pack dongle includes a portable housing, a wired battery pack connector, a controller, and a memory operatively connected to the controller and storing a high voltage battery pack status log. The battery pack dongle further includes a rechargeable battery maintained within the housing and electrically connected to the controller, and a user interface. The controller includes executable instructions which, when executed, cause the controller to receive, via the wired battery interface, state information from the high voltage battery pack, store the state information in the memory, and, based on the state information, generate one or more battery alerts at the user interface. The controller is further configured to communicate the state information to a remote system.

In a third example aspect, a method of monitoring a state of a battery pack via a dongle is provided. The method includes receiving battery state information from a battery management system of a high voltage battery pack at a battery pack dongle via a wired battery pack connector, the battery state information including one or more of battery status information and a battery safety alert. The method further includes storing, via a controller, the battery state information in a memory of the battery pack dongle. The method also includes, based on the battery state information obtained from the battery management system, generating, via the controller, a display indicative of the battery state information at a user interface of the battery pack dongle, the display being indicative of the battery safety alert.

This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

Non-limiting and non-exhaustive examples are described with reference to the following figures:

FIG. 1 illustrates an example diagram of a manufacturing and/or storage facility at which systems of the present disclosure may be employed.

FIG. 2 illustrates an example logical diagram illustrating communication of data among a plurality of manufacturing and/or storage facilities and a cloud storage and analysis application useable in conjunction with some embodiments of the present disclosure.

FIG. 3 is a front perspective view of a battery pack monitor, according to an example implementation.

FIG. 4 is a rear perspective view of a battery pack monitor, according to an example implementation.

FIG. 5 is a logical block diagram of a battery pack monitor according to the examples of FIGS. 3-4 .

FIG. 6 is a flowchart of a method of operation of a battery pack monitoring system in accordance with example aspects of the present disclosure.

FIG. 7 is a flowchart of a method of controlling display and storage of battery pack alerts at a battery pack monitor, in accordance with example aspects of the present disclosure.

FIG. 8 is a flowchart of a method of communicating updates to a battery pack dongle and/or a battery management system via a battery pack dongle, in accordance with example aspects of the present disclosure.

FIG. 9 is a block diagram of an example physical components of a computing device or system with which embodiments may be practiced.

DETAILED DESCRIPTION

As briefly described above, embodiments of the present invention are directed to a battery pack monitor, for example which may be electrically connected to a high voltage battery pack to receive state information from a battery management system of such a battery pack. The battery pack monitor receives battery state information from the battery management system. Battery state information can include battery status information, such as a state of charge (SOC) or state of health (SOH) of the battery, and may further include alerts generated by the battery management system indicative of a possible safety issue, such as thermal runaway. The battery pack monitor can log that state information and/or display status or alert information about the high voltage battery pack, for example by displaying or emitting an alert signal in the event of an alert, or otherwise displaying status information regarding thermal and charge properties such as temperature changes, operating temperature, voltage, and current, charge state, and the like. The battery pack monitor of the present disclosure is generally portable and may be easily electrically connected to a high voltage battery pack, in particular at a low voltage interface to the battery management system of such a battery pack. The battery pack monitor provides detectable feedback regarding safety alerts as well as operational status of the battery pack relative to its intended application, via visual and audio messages. The battery pack monitor may be powered via a rechargeable battery, and easily moved among high voltage battery packs to obtain state information associated with each.

In some instances, the battery pack monitor may be included within a networked battery pack monitoring system. In such cases, the battery pack monitor may be configured to communicatively connect with a remote system, such as a cloud server, to communicate battery state information; the remote system may receive such information associated with a plurality of battery packs and may analyze that data for purposes of warranty tracking, component quality assurance, performance trends, and the like. In addition, in some embodiments the battery pack monitor may wirelessly receive updates for a battery pack, and may communicate those updates to the battery management system.

The battery pack monitor provides a number of advantages within the context of storage and use or manufacturing of high voltage battery packs. For example, battery packs that are stored for a period of time prior to use or installation may be monitored to ensure that the state of charge and temperature remain within acceptable ranges. For example, a state of charge may be desired to not drop below a predetermined threshold, and temperature may be monitored to ensure it remains within the limits to avoid thermal runaway, or other alert conditions. Both voltage and temperature events may be logged, either locally or remotely, for subsequent analysis, for example to develop predictive and preventative maintenance protocols for such battery packs. Alert conditions may be communicated to a remote system, and/or to emergency response personnel, such as fire departments or other fire safety personnel. Additionally, operating data for various battery packs may be used by a vehicle manufacturer to better select the appropriate battery pack for a given application.

FIG. 1 illustrates an example diagram of a manufacturing and/or storage facility 10 at which systems of the present disclosure may be employed. In the example shown, the facility 10 may be a manufacturing facility for an electric vehicle (EV). In alternative examples, the facility 10 may be a storage facility at which high voltage battery packs usable within electric vehicles are stored or manufactured.

In the example shown, the facility 10 includes an electric vehicle manufacturing line 12 that receives parts from part suppliers, and various other manufacturing inputs. The manufacturing line 12 is designed for manufacturing an electric vehicle 14 that includes a high voltage battery pack. In the example shown, high voltage battery packs 50 may be assembled at the facility 10, or may be received at the facility from another facility, for example from a battery supplier or from another facility associated with the same enterprise as facility 10 but at which high voltage battery pack construction is performed. In the example shown, high-voltage battery cells 16 are received at a battery pack assembly and storage location 20. In this example, high-voltage battery pack 50 may be manufactured from the high voltage battery cell 16, as well as various other electronics. In examples, such high voltage battery packs 50 may include a plurality of high voltage battery cells 16, as well as a battery management system, and various other circuits and systems to perform charging, temperature and/or voltage regulation, and the like.

In the example as illustrated, the battery pack assembly and storage location 20 may retain a plurality of high voltage battery packs 50 prior to their inclusion within an electric vehicle, such as electric vehicle 14. As such, it may be advisable for the manufacturer or controller of the facility 10 to be able to understand the current charge, safety, and health status of one or more of those high-voltage battery packs 50, to ensure that quality components are incorporated within vehicles at the manufacturing lines 12.

For reference purposes, when a battery pack, such as a high voltage battery pack 50, is included within an electric vehicle, a vehicle control unit may be communicatively connected to a battery management system of the battery pack and may receive state information, for example representing operational status of the battery pack, as well as issues or alerts that may arise associated with that battery pack that may implicate potential safety issues. For example, a portion of the battery management system (typically a cell management unit, or CMU) may periodically wake up and check cell voltages or temperatures inside the battery pack and communicate any such information or alerts that may be relevant to a battery management unit (BMU) of the battery management system, which may in turn communicate any alerts with the vehicle control unit. However, for battery packs in storage, such notification capabilities are not present. Accordingly, the battery pack monitor, via its alarm interface and communication capabilities for connection to a remote (e.g., cloud) system, may communicate safety issues detected by the CMU to an outside environment or controller of the facility 10, thereby potentially improving alert visibility and accompanying safety response times.

Accordingly, a battery pack monitor is described herein that may be implemented as a dongle and may be easily moved to and electrically connected to a battery pack. The dongle or monitor may be battery-powered, and may be configured to capture and log status information regarding charge and health of the high-voltage battery pack 50. In some implementations, the monitor may allow for connection of other diagnostic equipment that may execute various tests on the state information obtained from the high-voltage battery pack 50. The dongle or monitor may also be configured for communication with a remote system, such as a cloud system. Such a cloud system may perform one or more analytic tests or assess trends in operation or error statuses of high voltage battery packs, and may communicate such information across one or more such facilities. In examples, notifications may be transmitted from either the battery pack monitor directly, or relayed by a remote system, to a manufacturing control and monitoring system 30, to ensure that any battery packs having significant safety hazard risks, or health or voltage issues indicative of a faulty battery pack, are not used within the manufacturing process, or to otherwise register health or voltage information associated with battery packs for purposes of audits, warranty, or other tracking processes. Additionally, safety alert information may be sent directly from a battery pack monitor, or via either a remote system or the manufacturing control and monitoring system 30, to emergency response personnel 90, such as fire response personnel. Furthermore operating parameters of such battery packs may be updated from remote systems, thereby simplifying the battery pack preparation process in the context of battery electric vehicle manufacturing.

FIG. 2 is an example logical diagram illustrating communication of data among a plurality of manufacturing and/or storage facilities and a cloud storage and analysis application useable in conjunction with some embodiments of the present disclosure. In the example shown, a plurality of facilities 10 may each be communicatively connected to a cloud storage location, such as virtual server 40. Each of the plurality of facilities 10 may correspond to facilities at which a dongle or monitor may be attached to one or more high voltage battery packs in accordance with the present disclosure. As such, various state information, including safety alert information, as well as state of charge (SOC) and state of health (SOH) information and other status information, may be collected and aggregated from a plurality of different high-voltage battery packs across a plurality of storage facilities or manufacturing facilities of an enterprise. In some examples, the virtual server 40 may communicate safety alert information to emergency response personnel 90, as discussed above. Additionally, in some examples, a remote computing system 80, operated by a user U may view a report 82 illustrating one or more of the analytics generated at the virtual server 40. The remote computing system 80 may be a computing system separate from the facilities 10, or may be a control system of the facilities 10, such as the manufacturing control and monitoring system 30. Further details regarding example analysis that may be performed on one or more high voltage battery packs using a battery pack monitor are provided below.

Referring now to FIGS. 3-4 , an example battery pack monitor 100 is illustrated according to an example implementation of the present disclosure. The battery pack monitor 100 may also be referred to as a battery pack dongle, as it is generally configured for wired connection to a high voltage battery pack, and is portable and movable within a facility for connection to a plurality of different high-voltage battery packs at different times, depending on the monitoring preferences or requirements of an enterprise or facility.

In the example shown, the battery pack monitor 100 comprises a portable housing 101 that includes a first side 102 and a second side 104. At the first side 102, a battery pack connector 106 provides a wired interface that is connectable between the battery pack monitor 100 and a corresponding connector of a high voltage battery pack 50. In examples implementations, the battery pack connector 106 comprises an SAE J1939-compliant connection interface, and includes both power and communication lines in a multi-conductor connection arrangement. At a second side 104 of the portable housing 101, the battery pack monitor 100 includes a diagnostics connector 110, a power supply connection 112, a flashlight 114, a status indicator 116, and programming buttons 118, shown as buttons 118 a-b. In example embodiments, the battery pack connector 106 may be located on an opposite side of the housing 101 from the diagnostics connector 110, power supply connection 112, flashlight 114, status indicator 116, and programming buttons 118. In other example embodiments, the various connectors and user interface elements (e.g., flashlight, status indicator, programming buttons, etc.) may be located on the same side of the housing 101, or on various other panel surfaces of the housing.

In the example shown, the diagnostic connector 110 may be configured to receive a wired connection between the battery pack monitor 100 and a diagnostic tool, such as an automated test system used to test high voltage battery systems by analyzing, for example, individual cell voltage or charge capacities, charge or discharge current of the overall high voltage battery pack 50, or various other characteristics.

The power supply connection 112 may receive a wired connection from a low voltage power supply, such as a 12 V or 24 V power supply, usable to recharge a battery retained within the housing. Such a battery is illustrated below in conjunction with FIG. 5 . The power supply connection 112 may be used to recharge the battery pack monitor 100, such that the battery pack monitor does not, when in use, require receipt of a separate power connection, either by being connected to a power source in proximity to the high-voltage battery pack to which it is connected, or by receiving electrical power from the battery pack itself.

The flashlight 114 may be used to indicate the presence of an alarm, and may be illuminated in the event of an error detected at the high voltage battery pack 50, or various charge or temperature readings being outside of a threshold as determined by the battery management system of the high voltage battery pack. Additionally, the status indicator 116 may provide a general charge status of the high-voltage battery pack, such that a user may readily determine current charge status visually. Additionally, buttons 118 may be used to test or reset the battery pack monitor 100, to initiate operation of particular tests, to communicate and intends to disconnect the monitor 100 from an associated battery pack, or the like. Various programming options may be provided. Accordingly, although to such buttons 118 a-b are shown, it is recognized that more than two buttons may be provided.

In addition, on a top side of the housing 101, a plurality of openings in the housing 101 may be provided to accommodate a siren 108. The siren 108 may be used to generate audible alarm sounds in the event of an emergency condition at the associated high voltage battery pack 50, such as a high temperature outside of a predetermined threshold where there may be risk of fire or damage. Other events may cause operation of the siren 108 as well.

In some examples, the battery pack monitor 100 may further include an antenna 130. In example implementations in which the battery pack monitor includes a wireless communication interface for communicating via Wi-Fi or cellular communication methods, the antenna 130 may be included, and used for purposes of assisting with sending and/or receiving such communications. For example, in some instances a battery pack monitor 100 may be configured to periodically transmit received state information from the battery management system that is logged within a memory of the battery pack monitor to a remote system such as a cloud storage system (e.g., virtual server 40). For example, a battery pack monitor 100 may be configured to transmit an alert to a remote system such as emergency response personnel (e.g., emergency response personnel 90 of FIGS. 1-2 ). In example embodiments where wireless communication interfaces are excluded, the antenna 130 may also be excluded.

Referring to the battery pack monitor 100 generally, the housing 101 is referred to herein as being handheld, in that it may be moved from place to place easily by a user for connection to comparatively larger, heavier battery packs. For example, the battery pack monitor 100 may be on the order of 1-4 inches in height, 4-8 inches in depth, and 4-12 inches in width, and may weigh on the order of 2-10 pounds. Other sizes or dimensions are possible as well, consistent with the principles of the present disclosure.

FIG. 5 is a logical block diagram of a battery pack monitor 100 according to the examples of FIGS. 3-4 . For purposes of illustration, the battery pack monitor 100 is illustrated as connected to a variety of external equipment and systems, including the high voltage battery pack 50, cloud storage such as virtual server 40, a diagnostic tool 202, a charger 220, and a local area network (LAN) 230. However, it is generally recognized that the battery pack monitor 100 corresponds to the analogous device as illustrated in FIGS. 3-4 , and that the various systems, other than the high-voltage battery pack 50, may be present only during some times of operation, or may be excluded entirely.

In the example shown, the battery pack monitor 100 includes an electronic control unit 120, also referred to herein as a controller. The electronic control unit (ECU) 120 may store instructions for its operation, and also is communicatively connected to a memory 122, which may store operating instructions for the ECU 120. The memory 122 may also store one or more logs 124 based on state information obtained from the high-voltage battery pack 50, in particular, from a battery management system 60 of the high-voltage battery pack.

In the example shown, the ECU 120 is connected to the high-voltage battery pack via the battery pack connector 106. In particular, the ECU 120 is connected to both a signal line and a power, or voltage line. The signal line may also be connected to the diagnostic connector 110, for purposes of passing data from the high-voltage battery pack 50 to a diagnostic tool 202.

For reference purposes, the high voltage battery pack 50 may have a variety of electrical connections and sensors internal thereto that are interfaced to the battery management system 60 and which are used to monitor status of the battery cells within that battery pack, as well as operational status of the battery pack overall. Example connections include battery pack positive and negative terminals, which the battery management system uses to monitor voltage and current flowing through the battery pack. Additionally, the battery management system 60 may include temperature sensors placed at various locations throughout the battery pack to monitor temperature of the battery cells. The battery management system 60 may use this information to adjust charging and/or discharging of the battery pack, to prevent overheating or underheating. Additionally, the battery management system 60 may be connected to a variety of current sensors that measure current flowing in and out of the battery pack, for example from a DC fast charger 210 that may be electrically connected to high voltage connectors of the battery pack 50. This information may be used by the battery management system 60 to calculate a state of charge (SOC) of the battery pack, and to control the charging and discharging of the battery pack. The battery management system 60 may also be connected to voltage sensors that measure the voltage at each cell of the battery pack, for example to balance the cells and ensure that they are charged and discharged evenly.

The high voltage battery pack 50 may include separate high voltage connection pins for connection to drive components of an electric vehicle once installed (shown as connected to the DC fast charger 210). In the context of the present application, a “high voltage” connection may relate to a connection at which a voltage above which control electronics typically operate. For example, high voltage may correspond to a voltage above about 25 volts, and in some instances above about 60 volts, where a low voltage connection will typically be below about 25 volts, such as a 24 volt connection, a 12 volt connection, and the like.

The signal lines included within the battery pack connector 106 between the battery management system 60 and the battery pack monitor 100 allow for communication of all of this gathered information (e.g., voltage, current, temperature, etc.) to the battery pack monitor 100 for storage in logs 124, for purposes of monitoring, alerting, and the like in a low cost, portable, simple manner. The power lines included in the battery pack connector 106 may be connected to an internal power source of the battery pack monitor 100, such as a rechargeable battery 150. The rechargeable battery 150 may provide power to the various components of the battery pack monitor 100, as well as to the battery management system 60 of the high voltage battery pack 50 via the power lines. In an example implementation, the battery pack connector 106, and optionally the diagnostic connector 110, are SAE J1939-compliant connection interfaces.

In some embodiments, the rechargeable battery 150 may be recharged via a charger 220 (e.g., a direct current 12 V or 24 V charger) that may be connected, during charging, at power supply connection 112. In other embodiments, the rechargeable battery 150 may be charged using electrical charge of the battery pack itself, e.g., from a connection to high voltage connectors of the battery pack 50.

In the example shown, the ECU 120 controls operation of the various status and communication capabilities of the battery pack monitor 100, including the flashlight 114, status indicator 116 (shown as status LEDs), program buttons 118, and siren 108. In some examples, one or more such indicators may be used in response to receipt of state information from a connected high voltage battery pack 50 indicating an alert condition. Alert conditions are generally determined at the battery management system 60 and logged therein for communication with external systems, and may include a voltage or current outside an expected threshold (e.g., too high or too low), as well as a temperature outside a threshold (again, too high or too low). In some examples, the thresholds used by the battery management system 60 are configurable to adjust to particular desired operating conditions of a battery pack. A low voltage or current level may result in display of a low capacity via the status indicator 116, while a high temperature (e.g., indicative of thermal runaway) or high voltage/current may trigger activation of the flashlight 114 or siren 108, as this may correspond to a more serious condition.

In some examples, the ECU 120 is further communicatively connected to a communication interface that includes an antenna 130. The antenna 130 may be configured for WiFi or cellular (e.g., 3G, 4G, or 5G connectivity) for transmitting data to a remote system, for example a cloud storage location such as a virtual server 40. The ECU may communicate logged state information, or may communicate only alert information obtained from the battery management system 60 of a battery to which it is connected. In some examples, the ECU 120 may be configured to communicate both such pieces of information via the antenna 130.

In addition, the antenna 130 may receive information from the cloud (virtual server 40) or local area network (LAN) 230, for example including update information to pass to the battery management system 60, or to communicate locally with other systems at the facility 10 where the high voltage battery pack is stored. In the example shown, the antenna 126 may receive an instruction from the cloud to control charging of the high voltage battery pack 50 to a predetermined state of charge; in such a case, the ECU 120 may control the antenna 126 to send remote charging actuation commands (e.g., via LAN 230) to a DC fast charger 210 that is electrically connected to the high voltage connections of the high voltage battery pack 50 to charge the battery cells therein to a desired charge state. For example, the battery pack monitor 100 may receive a command from a remote system to start or stop charging of the high-voltage battery pack 50 via the DC fast charger 210 based on the current charge states of the battery cells in the battery pack. Other types of commands or updates may be received as well, for example to adjust the desired thresholds for alarms or alerting in the battery management system 60 of the battery pack to which the battery pack monitor 100 is connected.

Referring to FIGS. 3-5 generally, it is noted that the battery pack monitor 100 is depicted as including a single battery pack connector 106 and set of user interface elements (e.g., flashlight, status indicator, programming buttons, etc.). However, a battery pack monitor 100 may include two or more such battery pack connectors 106 and/or sets of user interface elements. Furthermore, a set of user interface elements may be selectively useable in connection with multiple battery packs where more than one battery pack connector 106 is present, with buttons 118 useable to toggle among control or display of status and alert information for each such connected battery pack. Accordingly, where discussed herein as representing a connector or user interface, one or more such devices is contemplated.

Referring now to FIGS. 6-8 various flowcharts are illustrated depicting methods of use and operation of a battery pack monitor, such as the battery pack dongle described herein, in accordance with example embodiments. Referring first to FIG. 6 , a flowchart of a method 300 of operation of a battery pack monitoring system is provided. In this example method, the battery pack monitoring system includes a battery pack monitor, and may include, in some embodiments, remote storage (e.g., cloud storage), and/or other peripheral systems such as illustrated in FIG. 5 .

In the example shown, the method 300 includes detecting or being programmed to detect a connection to a battery management system (step 302). Detecting the connection to the battery management system, such as battery management system 60, can include detecting a connection, such as a power signal or a data signal, at the battery pack connector 106. It may also include receiving a trigger to begin monitoring, for example via one or more of the program buttons 118.

In the example shown, the method 300 also includes receiving battery state information from the battery management system (step 304). Receiving battery state information may include receiving information generated by the battery management system and output on an electrical cable connected between the high voltage battery pack 50 and the battery pack monitor 100. The battery state information may include information transmitted in accordance with an SAE J1939-compliant connection via the battery pack connector 106, and may include various temperature, voltage, current, alerting, and other parameters indicative of state of charge (SOC) and/or state of health (SOH) of the battery pack. In conjunction with receiving battery state information, the battery pack monitor will also store that information in a memory 122, for example in the form of operational logs 124.

In the example shown, the method 300 also includes determining whether the state information received from the battery pack includes one or more alerts (at operation 306). If the state information only includes operational data, and does not indicate the presence of any alerts (e.g., voltages or currents being outside of threshold ranges, a temperature outside of the threshold range, and the like) operational flow may return to continue monitoring and receiving battery state information, and logging that information in memory at step 304. Optionally, such information may be transmitted externally to the battery pack monitor, for example to a cloud storage system such as virtual server 40 described above.

In the example shown, if the status information indicates the presence of any alerts, the method 300 further includes generating one or more alarms based on the received state information (step 308). The specific alarms that are generated may be based on the particular alerts that are detected at the battery management system and transmitted to the battery pack, other 100. For example, the flashlight 114 may be illuminated or the siren 108 may be sounded in response to a temperature or voltage being outside of a particular threshold, in particular if well above a threshold. Furthermore, depending on the severity of the alert, the flashlight may be configured to illuminate with varying brightness or flashing patterns, and the siren 108 may be configured to output sounds of increasing volume with increasing alarm severity. Additionally, the status indicator 116 may be updated to indicate a current operational status of the battery pack, in particular the charge level or other current state information.

Transmitting state information and/or alert information may be performed at the time of receipt, or may be performed periodically, for example every 1-5 minutes. The selection of a particular timing for transmission of data to a remote system may be selected based on the intended application of that data. For example, if the data is to be used to alert personnel as to warning conditions occurring at the battery pack, the transmission may occur on a more frequent basis, while data used only for logging and subsequent analysis may be transmitted on a less frequent basis (e.g., every five minutes to one hour).

In the example shown, the method 300 may also include executing one or more cloud or diagnostic analytics (step 310). Generation of such analytics may be performed at the cloud system, such as the virtual server 40. Such analytics may be usable to identify individual battery packs that may be faulty or otherwise operate outside of an acceptable part quality standard. The virtual server 40 may be configured to communicate such information to a computing system, such as computing system 80 to alert a user U, who may initiate warranty repairs or initiate further diagnosis or inspection of faults of the battery pack (e.g., with a diagnostic tool 202, as described above). The virtual server 40 may also communicate directly back to a manufacturing control and monitoring system 30 that is used to monitor and manage manufacturing process, such that the faulty or failing battery pack will not be used during the manufacturing process prior to repair.

In the example shown, the method 300 may further include detection of disconnection of the battery pack monitor from a battery management system of a high voltage battery pack (step 312). If the battery pack monitor is not disconnected, operation may continue at step 304, to continue monitoring battery state information for alerts and/or status information as previously described. If the battery pack monitor is disconnected, operation may terminate until such time as another (or the same) battery pack is connected, at which time the battery pack monitor may detect connection to a battery management system and continue/resume monitoring of battery state information, e.g., at step 302.

FIG. 7 is a flowchart of a method 400 of controlling display and storage of battery pack alerts at a battery pack monitor, in accordance with example aspects of the present disclosure. The method 400 may be performed at the battery pack monitor, for example as part of steps 304-310 of FIG. 6 , above. In the example shown, the method 400 includes receiving battery state information from the battery management system (at step 402) and based on the battery management system identifying particular state information as being outside of predetermined thresholds, alerts may be communicated to the battery pack monitor. Accordingly, the battery pack monitor may generate any of a variety of alarms for notification of nearby personnel. In the example shown, a determination that a voltage is outside of threshold (at operation 404) may generate an output voltage alarm in the form of illumination of the flashlights 114 and/or sounding of the siren 108. Additionally, a determination that a temperature is outside of a threshold (at operation 406) may generate a alarms that the temperature is outside a threshold, again via flashlight 114 and/or siren 108. In the event one or more fault codes are detected at the battery management system (at operation 408), such fault codes may be displayed via flashing patterns or via alphanumeric characters included in the status indicator 116. Additionally, health data of the battery pack may be determined (at operation 410) and health alerts may be generated and/or stored within the memory 122. Furthermore, a state of charge being outside of a typical storage threshold state of charge (at operation 412) may result in display of a charge alert threshold at the status indicator 116.

In conjunction with any of the output alarms, alerts, and/or fault codes or logs, information may be stored within the memory 122 in the form of a log 124 (at step 414). The log 124 may be periodically the transmitted to a remote system for generating notifications and/or providing further analysis of any anomalous activity of the high-voltage battery pack 50. The method 400 may continue with further receipt of additional battery state information, e.g., at step 402.

FIG. 8 is a flowchart of a method 500 of communicating updates to a battery pack dongle and/or a battery management system via a battery pack dongle, in accordance with example aspects of the present disclosure. The method 500 may be performed using the battery pack monitor 100, in particular in instances where the battery pack monitor includes a wireless interface capable of communication with remote computing systems.

In the example shown, the method 500 includes receiving one or more updates from a remote system, such as a diagnostic tool 202 or from a cloud system, such as virtual server 40 (step 502). The one or more updates may include, for example, updates to the battery pack monitor or updates to be transmitted to the battery management system 60 of the high-voltage battery pack 50. In the case of the diagnostic tool 202, such a tool may be connected to the diagnostic connector 110 and data may be passed to, or through, the battery pack monitor 100 to the battery management system 60. In the case of the virtual server, data may be received at the antenna 126 and processed by the ECU 120 prior to application at either the battery pack monitor 100 or the battery management system 60.

Data that may be received for updating the battery pack monitor itself may include firmware updates, and the like. Additionally, the battery pack monitor may receive a communication to control operation of a DC fast charger 210, for example to adjust and/or maintain a charge state of the battery cells included in the battery pack within an acceptable range. Data that may be received for updating the battery management system may include updated thresholds regarding operational temperature, voltage, and current; updated information regarding when alerts should be generated based on observed charge or discharge status; updated fault codes, and the like.

The method 500 includes applying the updates to the battery pack monitor (at step 504) and/or at the battery management system (at step 506), as applicable. Upon completed application of the updates at the battery pack monitor 100 and/or the battery management system 60, a confirmation message may be returned to the diagnostic tool 202 or to the virtual server 40 (at step 508).

Referring to FIGS. 1-8 generally, it can be seen that in use, the battery pack monitor 100 may provide a variety of advantages in terms of improving visual inspectability of a battery pack by displaying charge and alert states of the battery pack easily to individuals at the facility. In particular, the visual inspect ability of the battery pack condition ensures that battery assembly is performed in an environment that maximizes safety for employees and surrounding area by providing early detection of safety issues associated with battery packs that are connected to such a monitor. The battery pack monitor may also log data for subsequent access and inspection, and exposes a diagnostics connector that allows a user to connect other diagnostic equipment to the same high voltage battery pack without first requiring disconnection of the battery pack monitor 100. Additionally, due to its compactness and portability (due to its relatively small size and lack of need for external power during monitoring), the battery pack monitor provides the data monitoring that would otherwise not be possible until a battery pack is installed within an electric vehicle and integrated into that vehicle's communication systems.

Furthermore, in those embodiments that include remote connectivity, for example to a cloud server such as virtual server 40, observed characteristics of the high voltage battery pack may be used to better track battery quality prior to installation within a vehicle and determine improved strategies for battery storage. Additionally, specific battery parameters may be programmed into the battery management system depending on the intended application for each battery pack. Such battery parameters may be programmed remotely via the battery pack monitor where communication capabilities are provided.

Still further, in applications outside of the manufacturing environment, such as where high-voltage battery packs are collected and reused after the end of their useful life within a battery electric vehicle as an energy storage bank system, the battery pack monitor may be used to determine the suitability of individual battery packs for such reuse, or to determine whether refurbishing or maintenance may be required. The battery pack monitor may also be used to reprogram operational parameters of the battery management system 60 in a battery pack when it is transitioned from use in a vehicle to use in such a power bank application.

FIG. 9 is a block diagram of an illustrative computing device 600 appropriate for use in accordance with embodiments of the present disclosure. The description below is applicable to the virtual server 40, the remote computing system 80, servers, personal computers, mobile phones, smart phones, tablet computers, embedded computing devices, and other currently available or yet-to-be-developed devices that may be used in accordance with embodiments of the present disclosure.

In its most basic configuration, the computing device 600 includes at least one processor 602 and a system memory 604 connected by a communication bus 606. Depending on the exact configuration and type of device, the system memory 604 may be volatile or nonvolatile memory, such as read-only memory (“ROM”), random access memory (“RAM”), EEPROM, flash memory, or other memory technology. Those of ordinary skill in the art and others will recognize that system memory 604 typically stores data or program modules that are immediately accessible to or currently being operated on by the processor 602. In this regard, the processor 602 may serve as a computational center of the computing device 600 by supporting the execution of instructions. According to one example, the system memory 604 may store one or more instructions 650 for analyzing or viewing state information from one or more high voltage battery packs, including alerts and status information regarding, for example, one or more state of charge (SOC) and state of health (SOH) parameters.

As further illustrated in FIG. 9 , the computing device 600 may include a network interface 610 comprising one or more components for communicating with other devices over a network (e.g., such as a battery pack monitor having a wireless communication interface as discussed above). Embodiments of the present disclosure may access basic services that utilize the network interface 610 to perform communications using common network protocols. The network interface 610 may also include a wireless network interface configured to communicate via one or more wireless communication protocols, such as WiFi, 2G, 3G, 4G, 5G, LTE, WiMAX, Bluetooth, or the like.

In the illustrative embodiment depicted in FIG. 9 , the computing device 600 also includes a storage medium 608. However, services may be accessed using a computing device that does not include means for persisting data to a local storage medium. Therefore, the storage medium 608 depicted in FIG. 9 is optional. In any event, the storage medium 608 may be volatile or nonvolatile, removable or non-removable, implemented using any technology capable of storing information such as, but not limited to, a hard drive, solid state drive, CD-ROM, DVD, or other disk storage, magnetic tape, magnetic disk storage, or the like.

As used herein, the term “computer-readable medium” includes volatile and nonvolatile and removable and non-removable media implemented in any method or technology capable of storing information, such as computer-readable instructions, data structures, program modules, or other data. In this regard, the system memory 604 and storage medium 608 depicted in FIG. 9 are examples of computer-readable media.

For ease of illustration and because it is not important for an understanding of the claimed subject matter, FIG. 9 does not show some of the typical components of many computing devices. In this regard, the computing device 600 may include input devices, such as a keyboard, keypad, mouse, trackball, microphone, video camera, touchpad, touchscreen, electronic pen, stylus, or the like. Such input devices may be coupled to the computing device 600 by wired or wireless connections including RF, infrared, serial, parallel, Bluetooth, USB, or other suitable connection protocols using wireless or physical connections.

In any of the described examples, data can be captured by input devices and transmitted or stored for future processing. The processing may include encoding data streams, which can be subsequently decoded for presentation by output devices. Media data can be captured by multimedia input devices and stored by saving media data streams as files on a computer-readable storage medium (e.g., in memory or persistent storage on a client device, server, administrator device, or some other device). Input devices can be separate from and communicatively coupled to computing device 600 (e.g., a client device), or can be integral components of the computing device 600. In some embodiments, multiple input devices may be combined into a single, multifunction input device (e.g., a video camera with an integrated microphone). The computing device 600 may also include output devices such as a display, speakers, printer, etc. The output devices may include video output devices such as a display or touchscreen. The output devices also may include audio output devices such as external speakers or earphones. The output devices can be separate from and communicatively coupled to the computing device 600, or can be integral components of the computing device 600. Input functionality and output functionality may be integrated into the same input/output device (e.g., a touchscreen). Any suitable input device, output device, or combined input/output device either currently known or developed in the future may be used with described systems.

In general, functionality of computing devices described herein may be implemented in computing logic embodied in hardware or software instructions, which can be written in a programming language, such as C, C++, COBOL, JAVA™, PHP, Perl, HTML, CSS, JavaScript, PythonScript, VBScript, ASPX, Microsoft.NET™ languages such as C #, or the like. Computing logic may be compiled into executable programs or written in interpreted programming languages. Generally, functionality described herein can be implemented as logic modules that can be duplicated to provide greater processing capability, merged with other modules, or divided into sub-modules. The computing logic can be stored in any type of computer-readable medium (e.g., a non-transitory medium such as a memory or storage medium) or computer storage device and be stored on and executed by one or more general-purpose or special-purpose processors, thus creating a special-purpose computing device configured to provide functionality described herein.

Many alternatives to the systems and devices described herein are possible. For example, individual modules or subsystems can be separated into additional modules or subsystems or combined into fewer modules or subsystems. As another example, modules or subsystems can be omitted or supplemented with other modules or subsystems. As another example, functions that are indicated as being performed by a particular device, module, or subsystem may instead be performed by one or more other devices, modules, or subsystems. Although some examples in the present disclosure include descriptions of devices comprising specific hardware components in specific arrangements, techniques and tools described herein can be modified to accommodate different hardware components, combinations, or arrangements. Further, although some examples in the present disclosure include descriptions of specific usage scenarios, techniques and tools described herein can be modified to accommodate different usage scenarios. Functionality that is described as being implemented in software can instead be implemented in hardware, or vice versa.

Many alternatives to the techniques described herein are possible. For example, processing stages in the various techniques can be separated into additional stages or combined into fewer stages. As another example, processing stages in the various techniques can be omitted or supplemented with other techniques or processing stages. As another example, processing stages that are described as occurring in a particular order can instead occur in a different order. As another example, processing stages that are described as being performed in a series of steps may instead be handled in a parallel fashion, with multiple modules or software processes concurrently handling one or more of the illustrated processing stages. As another example, processing stages that are indicated as being performed by a particular device or module may instead be performed by one or more other devices or modules.

The principles, representative embodiments, and modes of operation of the present disclosure have been described in the foregoing description. However, aspects of the present disclosure which are intended to be protected are not to be construed as limited to the particular embodiments disclosed. Further, the embodiments described herein are to be regarded as illustrative rather than restrictive. It will be appreciated that variations and changes may be made by others, and equivalents employed, without departing from the spirit of the present disclosure. Accordingly, it is expressly intended that all such variations, changes, and equivalents fall within the spirit and scope of the claimed subject matter. 

1. A battery pack monitor comprising: a portable housing; a controller within the housing; a memory communicatively connected to the controller; a power source positioned within the housing and operatively connected to the controller; and a battery pack connector comprising a wired battery interface electrically connectable between the controller and a battery pack management system of a high voltage battery pack; wherein the controller executes instructions to: receive, via the wired battery interface, state information from the high voltage battery pack; store the state information in the memory; and based on the state information, generate one or more battery alerts.
 2. The battery pack monitor of claim 1, wherein the battery pack connector electrically connects the power source to the battery pack management system, the battery pack connector including a plurality of signal lines, the plurality of signal lines including a power signal line and a communication signal line.
 3. The battery pack monitor of claim 2, further comprising a diagnostic connector operably connectable to a battery diagnostic tool, the diagnostic connector being connected to the communication signal line of the battery pack connector.
 4. The battery pack monitor of claim 1, further comprising a user interface including a status indicator and one or more programming buttons.
 5. The battery pack monitor of claim 4, wherein the status indicator identifies a charging state of the high voltage battery pack to which the battery pack monitor is connected.
 6. The battery pack monitor of claim 5, wherein the status indicator further includes an alarm indicator operable in response to the controller generating the one or more battery alerts.
 7. The battery pack monitor of claim 5, wherein the status indicator includes an alarm output including at least one of an audible siren or a flashlight, and wherein the alarm output is configured to be activated in response to a predetermined type of alert of the one or more battery alerts.
 8. The battery pack monitor of claim 1, wherein the power source comprises a rechargeable battery.
 9. The battery pack monitor of claim 8, further comprising a charging input connector electrically connected to the rechargeable battery.
 10. The battery pack monitor of claim 1, further comprising a wireless communication interface communicatively connected to the controller.
 11. The battery pack monitor of claim 10, wherein the wireless communication interface includes a wireless LAN and/or cellular data communication interface.
 12. The battery pack monitor of claim 11, wherein the communication interface includes an alarm output, the alarm output configured to communicate an alarm to emergency response personnel, the alarm output being activated in response to a predetermined type of alert of the one or more battery alerts.
 13. A battery pack monitoring system comprising: a battery pack dongle configurable for wired connection to a battery management system interface of a high-voltage battery pack, the battery pack dongle comprising: a portable housing; a wired battery pack connector; a controller; a memory operatively connected to the controller and storing a high voltage battery pack status log; a rechargeable battery maintained within the housing and electrically connected to the controller, the rechargeable battery being electrically connectable to the battery management system interface via the wired battery pack connector; and a user interface; wherein the controller is configured to: receive, via the wired battery interface, state information from the high voltage battery pack; store the state information in the memory; based on the state information, generate one or more battery status alerts at the user interface; and communicate the state information to a remote system.
 14. The battery pack monitoring system of claim 13, wherein the battery pack dongle further comprises a diagnostics connector electrically connectable to a diagnostics tool.
 15. The battery pack monitoring system of claim 13, wherein the user interface further includes a status indicator and one or more programming buttons.
 16. The battery pack monitoring system of claim 13, further comprising the remote system, wherein the remote system comprises a cloud server communicatively connected to the battery pack dongle and configured to receive the state information from the battery pack dongle, and wherein the cloud server is configured to analyze battery state information received from a plurality of high voltage battery packs via a plurality of battery pack dongles.
 17. The battery pack monitoring system of claim 13, wherein the rechargeable battery is configured to be recharged via the wired battery pack connector from a high voltage battery pack connected thereto.
 18. The battery pack monitoring system of claim 13, wherein the wired battery pack connector comprises a SAE J1939-compliant connection interface, and wherein the state information includes one or more state of charge (SOC) and state of health (SOH) parameter.
 19. A method of monitoring a battery pack via a dongle, the method comprising: receiving battery state information from a battery management system of a high voltage battery pack at a battery pack dongle via a wired battery pack connector; storing, via a controller, the battery state information in a memory of the battery pack dongle; based on the battery state information obtained from the battery management system, generating, via the controller, a display indicative of the battery state information at a user interface of the battery pack dongle, the display being indicative of the battery safety alert.
 20. The method of claim 19, further comprising communicating the battery state information to a cloud server via a wireless communication interface of the battery pack dongle. 